Apparatus and system for propeller blade forward retention

ABSTRACT

An apparatus and system for a marine propeller assembly are provided. A forward retention member that may be used with the marine propeller assembly includes a planar base, a drive shaft engagement end opposite the planar base, and a conic body extending therebetween along a centerline normal to the planar base. The forward retention member also includes at least one protuberance extending radially away from a surface of the conic body, the protuberance extending axially from the planar base arcuately convergent to a predetermined point between the planar base and the drive shaft engagement end.

BACKGROUND

The field of the disclosure relates generally to propulsion systems and, more particularly, to retaining propellers in a propeller hub.

At least some known propulsion systems, such as, marine propulsion systems, rely on a rotating propeller assembly including a central hub and propeller blades extending from the central hub. During operation, fluid generally flows across surfaces of the propeller assembly and through gaps defined between blades of the propeller assembly. Performance of the propeller assembly is highly dependent on the shape of the propeller assembly surfaces including those of the blades, central hub, and blade retaining members. As a result, propeller assemblies in which the shape of propeller assembly components are limited by construction methods, material limitations, component sizes, and the like, may result in sub-optimal flow characteristics, decreasing the efficiency of the propeller assembly and requiring more powerful drive systems to achieve required propulsion.

BRIEF DESCRIPTION

In one aspect, a forward retention member that may be used with propeller assembly includes a planar base, a drive shaft engagement end opposite the planar base, and a conic body extending therebetween along a centerline normal to the planar base. The forward retention member also includes at least one protuberance extending radially away from a surface of the conic body, the protuberance extending axially from the planar base arcuately convergent to a predetermined point between the planar base and the drive shaft engagement end.

In another aspect, a marine propeller assembly includes a hub including a forward face, an aft face, and a hub body extending therebetween, the hub configured to couple to a rotatable drive shaft, the hub further configured to receive a plurality of propeller blades spaced circumferentially around the hub. The marine propeller assembly also includes a forward retention member configured to couple to the forward face. The forward retention member includes a planar base, a drive shaft engagement end opposite the planar base, and a truncated conic body extending therebetween along a centerline normal to the planar base. The forward retention member further includes a central bore configured to receive a drive shaft and at least one protuberance extending radially away from a surface of the conic body, the protuberance extending axially from the planar base arcuately convergent to a predetermined point between the planar base and the drive shaft engagement end.

In yet another aspect, a marine propulsion system includes a rotatable drive shaft extending away from a hull of a water craft, a hub including a forward face, an aft face, and a hub body extending therebetween, the hub body formed of at least one of a metal material and a composite material, the hub body coupled to the drive shaft, the hub including a plurality of circumferentially-spaced composite propeller blades. The marine propulsion system also includes a forward retention member configured to couple to the forward face. The forward retention member includes a planar base, a drive shaft engagement end opposite the planar base, and a conic body extending therebetween along a centerline normal to the planar base. The marine propulsion system further includes at least one protuberance extending radially away from a surface of the conic body, the protuberance extending axially from the planar base arcuately convergent to a predetermined point between the planar base and the drive shaft engagement end.

DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 is a perspective view of a marine propeller assembly in accordance with an example embodiment of the present disclosure.

FIG. 2 is a side view of the marine propeller assembly shown in FIG. 1.

FIG. 3 is an exploded view of the marine propeller assembly shown in FIG. 1 in accordance with an example embodiment of the present disclosure.

FIG. 4 is an axial view, looking forward of a circumferential segment of the marine propeller assembly shown in FIG. 1.

FIG. 5 is an axial view of another embodiment of a marine propeller assembly.

FIG. 6 is a side elevation view of a marine propulsion system in accordance with an example embodiment of the present disclosure.

FIG. 7 is an axial view looking aft of the marine propulsion system shown in FIG. 6 in accordance with the example embodiment of the present disclosure.

Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of this disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.

DETAILED DESCRIPTION

In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged; such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

As used herein, the terms “axial” and “axially” refer to directions and orientations that extend substantially parallel to a centerline of the propulsion shaft or propeller hub. Moreover, the terms “radial” and “radially” refer to directions and orientations that extend substantially perpendicular to the centerline of the propulsion shaft or propeller hub. In addition, as used herein, the terms “circumferential” and “circumferentially” refer to directions and orientations that extend arcuately about the centerline of the propulsion shaft or propeller hub.

Embodiments of the marine propeller assemblies and systems described herein provide a cost-effective method for reducing the weight of marine propellers as compared to those that are currently available. The marine propeller assemblies and systems also provide hydrodynamics efficiencies not found in current propeller assemblies. As opposed to monolithic cast and machined propeller assemblies, some embodiments of the marine propeller assemblies described herein are formed of a composite material laid over an internal structural frame and/or a filler material, such as, but not limited to a structural foam filler. The blades are formed individually and coupled to a metallic hub coupled to a drive shaft of a marine vessel. The separable blades provide a manageable weight and size for maintenance of the propeller system. The separable blades are retained in a dovetail groove configured to receive a dovetail of each blade. Axially, the blades are retained by an axial retention member couplable to the hub and configured to abut an end face of a dovetail associated with each blade. The axial tension or force used to secure each dovetail axially may be adjustable based on an axial bias member formed either in the end face of the dovetail or in the surface of the axial retention member adjacent the dovetail end face. The blades are retained radially and circumferentially using wedges configured to engage a dovetail sidewall and be coupled to the hub using fasteners.

In one embodiment, a forward retention member is coupled to a forward end of the hub system, which is formed in a three-dimensional (3-D) truncated conic shape and also provides axial retention for the separable blades. The conic shape is truncated because the apex of the conic shape and portion of the length of forward retention member is removed to permit fitting the forward side of the forward retention member onto the drive shaft of the marine propeller assembly. In addition to providing axial retention of the separable blades in the hub, the forward retention member also provides hydrodynamic benefits and improves performance of the propeller assembly. The forward retention member includes contours or protuberances that transition the conic shape of the body of the forward retention member into the airfoil shape of the blade to promote efficient hydrodynamic flow through the marine propeller assembly. Such performance improvement may relate to (i) an amount of cavitation during operation; (ii) generated thrust; (iii) open water efficiency; (iv) hull efficiency; (v) relative rotative efficiency; (vi) mechanical efficiency; (vii) a quasi-drive coefficient; and (viii) acoustic efficiency.

Because the blades may be retained in a spiral or arcuate groove in the hub and the root of the blade may include a twist in its root, the transitional contour or protuberances also extends these characteristics from the blade in diminishing fashion to the surface of the forward retention member. In various embodiments, the forward retention member is formed of metal and in some other embodiments, the forward retention member is formed of composite material with or without an internal structural frame.

FIG. 1 is a perspective view of a marine propeller assembly 100 in accordance with an example embodiment of the present disclosure. In the example embodiment, marine propeller assembly 100 includes a hub 102, a plurality of wedges 104, and a plurality of separable blades 106.

Hub 102 includes a first or forward face 108, a second or aft face 110 (not shown in FIG. 1, facing away from the view in FIG. 1), and a hub body 112 extending between first face 108 and second face 110. In the example embodiment, first face 108 is spaced axially forward of second face 110. Hub body 112 includes a central bore 114 that is axisymmetric with an axis of rotation 116 of marine propeller assembly 100. Bore 114 includes a radially inner bore surface 118 having an internal diameter (ID) 120. Hub 102 includes a radially outer hub surface 122 having an outer diameter (OD) 124. In one embodiment, outer hub surface 122 includes a plurality of dovetail grooves 126 that extend radially inwardly from outer hub surface 122 a predetermined depth 128. Each of the plurality of dovetail grooves 126 extend generally axially along hub body 112 from first face 108 to second face 110. Each of the plurality of dovetail grooves 126 includes a first undercut sidewall 130 and a second sidewall 132 spaced apart circumferentially. Each of the plurality of dovetail grooves 126 is configured to receive a respective wedge 104 of the plurality of wedges 104 and a dovetail 127 of respective blade 106 of the plurality of separable blades 106.

FIG. 2 is a side view of marine propeller assembly 100. In the example embodiment, a first detail 200 of hub 102 illustrates dovetail groove 126 that extends straight axially between first face 108 and second face 110 parallel to axis of rotation 116. A second detail 202 illustrates dovetail groove 126 that extends linearly at a skew angle 204 between first face 108 and second face 110. A third detail 206 illustrates dovetail groove 126 that extends arcuately between first face 108 and second face 110.

FIG. 3 is an exploded view of marine propeller assembly 100 in accordance with an example embodiment of the present disclosure. In the example embodiment, hub 102 is illustrated with plurality of dovetail grooves 126 extending arcuately between first face 108 and second face 110. A blade 106 is illustrated cutaway showing an interior frame structure 300 that may be used in one embodiment. Interior frame structure 300 includes a plurality of structural frame members 302 coupled together at respective frame joints 304. In various embodiments, dovetail 127 is formed of a metallic material or a composite material and coupled to a respective composite blade portion 306 of a respective blade 106 of plurality of blades 106. In other embodiments, each blade 106 may be formed using interior frame structure 300, which may be at least partially surrounded by a filler material, such as, but not limited to, a foamed material 308.

FIG. 4 is an axial view, looking forward of a circumferential segment 400 of marine propeller assembly 100 (shown in FIG. 1). In the example embodiment, dovetail 127 is retained in dovetail groove 126 by undercut sidewall 130 engaging a complementary first dovetail sidewall 401 and by a first wedge sidewall 402 engaging a complementary second dovetail sidewall 404. Wedge 104 is retained in dovetail groove 126 by one or more fasteners, such as, but not limited to, one or more threaded fasteners 406, for example, one or more bolts. In the example embodiment, a head 408 of fastener 406 is countersunk into a radially outer surface of wedge 104.

FIG. 5 is an axial view of another embodiment of a marine propeller assembly 500. In the example embodiment, a hub 502 includes a central bore 504 configured to receive a propulsion drive shaft 506 therethrough. In some embodiments, hub 502 is keyed onto propulsion drive shaft 506 using, for example, but not limited to, a keyed joint 508 including a keyway 510, a keyseat 512, and a key 514. Keyed joint 508 is used to connect hub 502 to propulsion drive shaft 506. Keyed joint 508 prevents relative rotation between hub 502 and propulsion drive shaft 506 and facilitates torque transmission between hub 502 and propulsion drive shaft 506. In one embodiment, an outer radial surface 516 of hub 502 includes a plurality of circumferentially-spaced flats 518. Each flat is configured to receive a blade dovetail 520 or a wedge 522. Specifically, flats 518 are generally planar surfaces that are complementary to a planar radially inner surface 524 of dovetail 520 and a radially inner surface 526 of wedge 522. In various embodiments, flats 518 and surfaces 524 and 526 have contoured surfaces that are complementary with respect to each other. For example, flats may include a generally concave contour while surfaces 524 and 526 include a generally convex contour and vice versa. Other contours may be used and each contour may be a simple contour or may be a complex contour. Blade dovetail 520 is retained against hub by wedges 522 positioned on either circumferential side of blade dovetail 520. Sidewall 528 of wedges 522 are undercut to provide an interference fit with complementary sidewalls 530 of blade dovetail 520. Wedges 522 are retained against hub 502 using for example, fasteners 532, such as, but not limited to threaded fasteners, for example, bolts. In one embodiment, a head 534 of fastener 532 is countersunk into a radially outer surface 536 of wedge 522.

FIG. 6 is a side elevation view of a marine propulsion system 600 in accordance with an example embodiment of the present disclosure. In the example embodiment, marine propulsion system 600 includes a marine propeller assembly 602 such as, but not limited to marine propeller assembly 100 (shown in FIG. 1) coupled to a rotatable propulsion drive shaft 506 extending away from a hull of a water craft (not shown in FIG. 6), such as, a cargo ship or tanker. Marine propeller assembly 602 includes hub 102 including forward face 108 wherein “forward” is with respect to a forward direction 603, aft face 110 wherein “aft” is with respect to an aft direction 605, and hub body 112 extending therebetween. In some embodiments, hub body 112 is formed of a metal material, such as, but not limited to marine bronze, nickel copper (NiCu) and alloys thereof, and the like. In other embodiments, hub body 112 is formed of a composite material. Hub body 112 is typically coupled to propulsion drive shaft 506 using a key system (shown in FIG. 5). Hub 102 includes a plurality of circumferentially-spaced propeller blades 106. Marine propeller assembly 602 also includes a forward retention member 604 configured to couple to forward face 108. Forward retention member 604 includes a planar base 606, an opposing drive shaft engagement end 608, and a truncated conic body 610 extending therebetween along axis of rotation 116, which is approximately normal to planar base 606. Forward retention member 604 also includes at least one protuberance 612 extending radially away from a surface 614 of conic body 610. Protuberance 612 extends axially from planar base 606 arcuately convergent to a predetermined point 616 between planar base 606 and a forward axial extent 618 of drive shaft engagement end 608. Predetermined point 616 is positioned a predetermined axial distance 620 forward of planar base 606. Protuberances 612 are embodied as blade extensions configured to hydrodynamically transition a shape of conic body 610 to a shape of a respective propeller blade 106 of plurality of propeller blades 106. In one embodiment, conic body 610 and at least one protuberance 612 are integrally-formed. In other embodiments, at least one protuberance 612 is separately attached to conic body using for example, fasteners, adhesives, and/or weldments.

In various embodiments, propeller blades 106 are formed of a composite structure that includes dovetail 127 (shown in FIG. 1) formed of, for example, a metal material or a composite material and coupled to a plurality of structural frame members 302 coupled together to form an interior frame structure 300 (shown in FIG. 3). A filler material 308, such as, a structural foam is positioned between plurality of structural frame members 302. The filler material could also be the only component inside the propeller blade. A plurality of tows (not shown in FIG. 6) of composite material at least partially surround interior frame structure 300 and filler material 308 (shown in FIG. 3) to form an outer structure of each of propeller blades 106. In one embodiment, plurality of composite propeller blades 106 are joined to hub 102 using dovetail 127 and dovetail groove 126 joint (both shown in FIG. 1). In other embodiments, plurality of composite propeller blades are joined to hub 102 using dovetail 520 and dovetail wedge 522 joint (shown in FIG. 5). Additionally, protuberances are configured to continue a 3-D spiral or twist of blade 106 proximate a forward end 622 of blade 106.

FIG. 7 is an axial view looking aft of marine propulsion system 600 in accordance with an example embodiment of the present disclosure. In the example embodiment, marine propulsion system 600 includes a marine propeller assembly 602 such as, but not limited to marine propeller assembly 100 (shown in FIG. 1) coupled to a rotatable propulsion drive shaft 506 extending away from a hull of a water craft (not shown in FIG. 6), such as, a cargo ship or tanker. In some embodiments, hub body 112 (hidden behind forward retention member 604 in FIG. 7) is coupled to propulsion drive shaft 506 using, for example, a key system (shown in FIG. 5). Hub 102 includes a plurality of circumferentially-spaced propeller blades 106. Marine propeller assembly 602 also includes forward retention member 604 configured to couple to forward face 108 (hidden behind forward retention member 604 in FIG. 7). Forward retention member 604 includes a planar base 606, an opposing drive shaft engagement end 608, and a truncated conic body 610 extending therebetween along axis of rotation 116, which is approximately normal to planar base 606. Forward retention member 604 also includes at least one protuberance 612 extending radially away from a surface 614 of conic body 610. Protuberance 612 extends axially from planar base 606 arcuately convergent to a predetermined point 616 between planar base 606 and a forward axial extent 618 of drive shaft engagement end 608. Predetermined point 616 is positioned a predetermined axial distance 620 forward of planar base 606. Protuberances 612 are embodied as blade extensions configured to hydrodynamically transition a shape of conic body 610 to a shape of a respective propeller blade 106. In one embodiment, conic body 610 and at least one protuberance 612 are integrally-formed. In other embodiments, at least one protuberance 612 is separately attached to conic body using for example, fasteners, adhesives, and/or weldments.

An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) forward axial retention for separable marine propeller blades, (b) a hydrodynamically efficient and streamlined conic shape, (c) 3D contours of the forward axial retention member transition the shape of the forward axial retention member to the shape of the associated propeller blade, and a 3D spiral introduction to the blade shape.

The above-described embodiments of an apparatus and system of retaining a separable composite marine propeller assembly on a propulsive or drive shaft of a watercraft provides a cost-effective and reliable means for operating and maintaining the marine propeller assembly. More specifically, the apparatus and system described herein facilitate maintaining an axial position of the marine propeller assembly on the shaft while providing a hydrodynamically streamlined flow path for water over the marine propeller assembly. As a result, the apparatus and system described herein facilitate operating a large commercial water craft in a cost-effective and reliable manner.

Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

What is claimed is:
 1. A forward retention member for a propeller assembly, said forward retention member comprising: a planar base, a drive shaft engagement end opposite said planar base, and a conic body extending therebetween along a centerline normal to said planar base; and at least one protuberance extending radially away from a surface of said conic body, said protuberance extending axially from said planar base arcuately convergent to a predetermined point between said planar base and said drive shaft engagement end.
 2. The forward retention member of claim 1, wherein said conic body is truncated at said drive shaft engagement end.
 3. The forward retention member of claim 1, wherein said at least one of said conic body and said protuberance are at least partially formed of a composite material.
 4. The forward retention member of claim 1, wherein said protuberance is configured to align with a complementary hub protuberance of a propeller assembly hub.
 5. The forward retention member of claim 1, wherein said conic body and said at least one protuberance are integrally-formed.
 6. The forward retention member of claim 1, further comprising a central bore configured to receive a drive shaft.
 7. The forward retention member of claim 1, wherein said planar base is configured to couple to a complementary planar hub surface of a propeller assembly hub.
 8. A marine propeller assembly comprising: a hub comprising a forward face, an aft face, and a hub body extending therebetween, said hub configured to couple to a rotatable drive shaft, the hub further configured to receive a plurality of propeller blades spaced circumferentially around said hub; a forward retention member configured to couple to said forward face, said forward retention member comprising: a planar base, a drive shaft engagement end opposite said planar base, and a truncated conic body extending therebetween along a centerline normal to said planar base; a central bore configured to receive a drive shaft and at least one protuberance extending radially away from a surface of said conic body, said protuberance extending axially from said planar base arcuately convergent to a predetermined point between said planar base and said drive shaft engagement end.
 9. The marine propeller assembly of claim 8, wherein said conic body is at least partially formed of a composite material.
 10. The marine propeller assembly of claim 8, wherein said protuberance is at least partially formed of a composite material.
 11. The marine propeller assembly of claim 8, wherein said protuberance is configured to hydrodynamically transition a shape of the conic body into a shape of a respective propeller blade of the plurality of propeller blades.
 12. The marine propeller assembly of claim 8, wherein said conic body and said at least one protuberance are integrally-formed.
 13. The marine propeller assembly of claim 8, wherein said conic body is at least one of centrifugal catenary-shaped and arcuate A-frame shaped in cross-section.
 14. The marine propeller assembly of claim 8, wherein said planar base is configured to couple to a complementary planar hub surface of a propeller assembly hub.
 15. A marine propulsion system comprising: a rotatable drive shaft extending away from a hull of a water craft; a hub comprising a forward face, an aft face, and a hub body extending therebetween, said hub body formed of at least one of a metal material and a composite material, said hub body coupled to said drive shaft, said hub comprising a plurality of circumferentially-spaced composite propeller blades; and a forward retention member configured to couple to said forward face, said forward retention member comprising: a planar base, a drive shaft engagement end opposite said planar base, and a conic body extending therebetween along a centerline normal to said planar base; and at least one protuberance extending radially away from a surface of said conic body, said protuberance extending axially from said planar base arcuately convergent to a predetermined point between said planar base and said drive shaft engagement end.
 16. The marine propulsion system of claim 15, wherein at least some of said plurality of composite propeller blades comprise: a cavity formed in an interior space of the composite propeller blades; and a filler material at least partially filling said cavity.
 17. The marine propulsion system of claim 15, wherein at least some of said plurality of composite propeller blades comprise a dovetail formed of at least one of a metal material and a composite material.
 18. The marine propulsion system of claim 15, wherein at least some of said plurality of composite propeller blades comprise: a plurality of structural members coupled together to form an interior propeller frame; a filler material positioned between said plurality of structural members; and a plurality of tows of composite material at least partially surrounding said interior propeller frame and said filler material.
 19. The marine propulsion system of claim 15, wherein said protuberances comprise blade extensions configured to hydrodynamically meld a shape of a respective propeller blade of the plurality of propeller blades into a shape of the conic body.
 20. The marine propulsion system of claim 15, wherein said conic body is truncated at said drive shaft engagement end. 